pneumatic machine to set eyelets and washers

OPERATING MANUAL
PNEUMATIC MACHINE TO SET EYELETS
AND WASHERS
IMAGE PERFECT MODEL: EP - 200
WARNING:
SPANDEX DECLINES ANY LIABILITY ABOUT THE INCORRECT USE OR
MISUNDERSTUNDING ABOUT THIS OPERATING MANUAL.
INDEX
1
INTRODUCTION. ....................................................................................... 3
1.1
1.2
2
TECHNICAL DATA...................................................................................... 4
2.1
2.2
3
INSTALLATION POSITION REQUIREMENTS. ........................................................... 5
PENUMATIC INSTALLATION. ................................................................................ 5
TRANSPORT....................................................................................................... 5
UNLOADING AND LEVELLING. .............................................................................. 6
LIGHTING CONDITIONS. ..................................................................................... 6
LEARNING INSTRUCTIONS. ................................................................................. 6
MACHINE OPERATION............................................................................... 8
4.1
4.2
4.3
4.4
5
MACHINE SPECIFICATIONS AND OPERATION. ........................................................ 4
MAIN TECHNICAL DATA....................................................................................... 4
INSTALLATION. ........................................................................................ 5
3.1
3.2
3.3
3.4
3.5
3.6
4
INTRODUCTION. ................................................................................................ 3
MACHINE IDENTIFICATION AND “CE” MARKING. .................................................... 3
MACHINE DESCRIPTION. ..................................................................................... 8
CHECKING THE MACHINE BEFORE STARTING. ....................................................... 8
EYELET SETTING. ............................................................................................... 8
OTHER MACHINE APPLICATIONS. ......................................................................... 9
ADJUSTMENTS. ....................................................................................... 10
5.1
WARNINGS ABOUT THE ADJUSTMENTS. .............................................................. 10
5.2
DIES CHANGING (SAME OR DIFFERENT EYELET DIMENSION). ............................... 10
5.3
SAFETY RING ADJUSTMENTS FOR DIFFERENT THICKENES......... Error! Bookmark not
defined.
6
MANTEINANCE........................................................................................ 13
7
FAILURES. .............................................................................................. 14
7.1
8
SAFETY. .................................................................................................. 15
8.1
9
TROUBLESHOOTING. ........................................................................................ 14
SAFETY DEVICES.............................................................................................. 15
ANNEX. ................................................................................................... 16
9.1
9.2
9.3
9.4
SPARE PART LISTIG. .........................................................................................
SUPPLIED TOOLING. .........................................................................................
PNEUMATIC DRAWING. .....................................................................................
GUARANTIES. ..................................................................................................
16
16
16
17
1 INTRODUCTION.
1.1 INTRODUCTION.
This machine has been designed to set eyelets and washers, making in just one operation the cutting and
setting. This unit has been specially manufactured to set Image Perfect plastic eyelets.
EP-200 can set eyelets on materials such us PVC coated material and in general terms on plasticized fabrics. It
will not work on fabrics as cotton or polyester.
The standard eyelets holes are Ø8, Ø12 and Ø16 mm.
WARNINGS:
Lack of knowledge about the machine usually will lead operator to elemental doubts
about its operation.
Please read carefully this operating manual to safety operate the machine and to
optimize machine’s capability.
-
1.2 MACHINE IDENTIFICATION AND “CE” MARKING.
Each machine has a data plate on the side, made on aluminum. The following specifications are on it:
-
Manufacturer’s name and data.
-
Year of production.
-
Model and serial number.
-
Maximum air pressure (in bars).
-
“CE” mark.
-
Weight.
2 TECHNICAL DATA.
2.1 MACHINE SPECIFICATIONS AND OPERATION.
The machine consists on a metal head where all the parts are placed (fix and moving ones), such us pneumatic
cylinder, axle, setting dies, safety devices, etc and a pneumatic pedal.
This unit has been designed to bolt it to the customer’s work bench. EP-200 can be also mounted on a plastic
(PE) table with four wheels (MIPEP202) on the corners, all of them with breaking system. Installing EP-200 on
wheels can help to move the eyelet-press around large banners.
Once the machine has been place on its permanent location, without fitting the air hosepipe into the
connection, verify that it has not suffered any blow or breakage while being transported and it has not any
loose parts.
The operation of the machine is very simple:
(F)
(A)
(E)
(B)
(X)
(C)
(D)
Fig. 1
1.
Operator will open the air inlet valve “A”, placing manually the eyelet through the top die “B” and
washer on the bottom die “C” and then put the banner over it.
2. When pressing down the pedal “D”, a pneumatic cylinder is set in motion, making the safety ring “E”
to come down up to the safety height preventing the access of operator’s hands to the setting area “X”
and activates the micro end of race which sets the main pneumatic cylinder in motion.
3.
The axle of the main pneumatic cylinder “F” will come down. Attached to its lower part, there is the
top die “B”. The aim of the downward movement of the axle is to cut a hole on the material with the
top die and as an effect of the pressure that the top die “B” puts on the bottom one “C”, to roll the
eyelet over the washer.
4.
After the eyelets is set, all parts will return to its starting position, leaving the machine ready for
another cycle as soon as we place again the eyelet, washer and banner
2.2 MAIN TECHNICAL DATA.
The main technical data of this machine are:
Width x Depth x Height
Weight
Air pressure
24 cm x 32 cm x 41 mm.
28,5 Kg / 63 Pounds.
6 bars / 87 psi.
3 INSTALLATION.
3.1 INSTALLATION POSITION REQUIREMENTS.
The minimum space recommended must be sufficient to keep that safety space in all directions for the operator
to work properly.
WARNINGS:
Please note that that both the electrical wire and the air hosepipe should never be completely stretched.
3.2 PNEUMATIC INSTALLATION.
The machine has an air inlet valve, type quick acting coupler (ISO 6150-B standard) ∅8 mm, located in the
back of the machine (A).
(A)
Fig. 2
For an optimal operation, the supply of compressed air should be 6 Kg/cm2. It is important, especially when
working with Ø16mm eyelets that the pressure doesn’t drop after one of two settings as the machine might not
have enough power to close the eyelet. If this happens you will require a bigger compressor with more power.
We recommend that the flexible air hosepipe from the compressor or pneumatic installation comes from the top
of the building to avoid operator’s injuries or damages on the equipment.
3.3 TRANSPORT.
To transport the machine to its permanent location, due to its low weight (around 10 Kilos), it is not necessary
to use a forklift, but the following precautions should be taken in account:
-
Use protective gloves.
Lift the load gently.
Do not make sudden movements.
The machine is delivered with appropriate packaging to avoid shocks and frictions during transport.
In the event that for some reason it is necessary to transport again the machine after its installation and the
customer does not have the original packaging, we advice to use a reinforced package (wood or cardboard).
3.4 UNLOADING AND LEVELLING.
Due to its low weight it can be unloaded by hand, always following the steps stayed on paragraph 3.3 and
holding the box firmly.
Once the machine is on the ground and totally unpacked, it can be lifted manually with one hand on the “body
of the machine” and another one on the “handgrip” towards its permanent location.
The work bench or permanent location of the machine must be strong enough and if possible leveled. Before
any operation with the equipment, the machine must be properly fixed to the bench (from the customer) with 4
M8 screws (8.8 quality), washers and self-locking nuts.
3.5 LIGHTING CONDITIONS.
A safe operation and servicing of the machine requires a minimum lighting of 300 lux.
3.6 LEARNING INSTRUCTIONS.
The following set of instructions and warnings about EP-200 should always be taken in account:
-
Before connecting the machine to the compressor or to customer’s pneumatic installation, it should be
place on its permanent location.
-
The cleaning, handling or replacement of parts should be made with the air inlet valve “A” shut.
-
Do not remove from the machine the safety devices, stickers or warning sings that point out
dangerous areas. In case of withdrawal by force majeure, please remember to place them back before
using the machine again.
-
The machine has an air inlet valve “A” (see Fig. 1) to manually open and close the air supply to the
pneumatic cylinder “F” (fig. 1); When the machine is not in use, it should be shut (see fig. 26), to
avoid accidents when use by a third party. We also suggest disconnecting the hosepipe from the
compressor for safety reasons.
The dangerous area of the machine is the cutting and setting area that is protected by a safety ring and the
stainless steel plate. Never access this area with the air inlet valve open “A” on OPEN position.
(Setting area “X”)
Fig. 3
Operator should pay attention to the position of the air inlet valve (H) (See Fig. 1) located on the back
of the machine. When the valve changes its position from open to close, the compressed air on the
internal circuit of the machine is expelled, preventing any unexpected action from the pneumatic
cylinder if by accident the pedal is pressed.
CLOSE position
Fig. 4
OPEN position
Fig. 5
4 MACHINE OPERATION.
4.1 MACHINE DESCRIPTION.
This machine has been designed to set eyelets (grommets) with washers, feeding the machine by hand, on PVC
coated material and in general terms on plasticized fabrics but not on fabrics as it might create wrinkles due to
its setting system. The maximum cutting diameter is 16 mm (the machine is supplied, adjusted and ready to
use with the eyelet size required by customer on its order).
The machine cuts the material and sets the eyelet in just one operation. Each set of dies has been designed to
work with only one eyelet size with its washers, the models may differ on:
⇒
⇒
EYELET
o
o
o
(G):
Head diameter “D”.
Eyelet height “L”.
Internal hole diameter “d”.
(G)
WASHER (H):
o
Outside diameter “F”.
o
Washer height “H”.
o
Internal hole diameter “i”.
(H)
Fig. 6
If you need to set different eyelet sizes, you will require different setting dies.
PLASTIC TECH DEVELOPMENTS, S.L. disclaims any responsibility when using the machine for different uses
than the ones covered on this operating manual.
4.2 CHECKING THE MACHINE BEFORE STARTING.
Before using the machine for the first time, or when the location of the machine is changed, or adjustments or
part replacements are made, we advice customers to check that the machine has not suffered a blow or
breakage.
4.3 EYELET SETTING.
1.
2.
Check that the air inlet valve “H” is on OPEN position (fig. 5).
Place the eyelet “G” gently through the top die “B”. Place the washer “H” on the bottom die
with the teeth looking upwards.
(G)
(H)
Fig. 7
3.
Place the banner over the stainless steel plate holding it with both hands.
4.
Press the pneumatic pedal (D). First, the safety ring “E” will come down and as reached its stroke with
no objects interfering, the inside micro end of race will launch the main pneumatic cylinder making the
to die “B” to come down.
5.
All the moving parts will return no its original position and machine will be ready for a new eyelet
setting.
4.4 OTHER MACHINE APPLICATIONS.
To cut holes on the material, without setting eyelets, it will not be necessary to install specific
tooling; it will be possible to make it with the same ones use to set the eyelets. Hole diameter will
not be more than 16mm.
5 ADJUSTMENTS.
5.1 WARNINGS ABOUT THE ADJUSTMENTS.
The parts that should be replaced on a regular basis due to normal wear are the cutting or bottom die “C” and
setting or top die “B”. We will see that the parts need to be replaced when either the cutting or the setting is
not accurate. We always recommend having a spare set of these parts on your stock.
(C)
(B)
Fig. 8
When doing maintenance operations if by any reason it is necessary to remove parts meant for operator safety
(safety protection, stainless steel plate ...) remember to put them back where they belong and fasten them
firmly.
WARNING: Shut the general air inlet valve to CLOSE position (see Fig. 4) to change dies, install optional
equipment or any other handling.
5.2 DIES CHANGING (SAME OR DIFFERENT EYELET DIMENSION).
Whenever is necessary to replace the dies for its normal wear or for a new size, you should follow
these steps:
WARNING:
To install a new set of dies it will be necessary at some point to manipulate the setting area “X” (see Fig.
3).
Please be very careful while doing adjustments, always making sure that your hands and fingers are out
of the setting area (X) (see Fig.3) and that nobody can press the `pedal “D” that will start the setting
operation catching hand or fingers.
Press down the safety pedal “D” and without
releasing your feet from in, close the air inlet valve
“A”. Doing it this way the axle of the cylinder will
descend and stay on its lower position.
When the valve changes its position from open to
close, the compressed air on the internal circuit of
the machine is expelled, preventing any unexpected
action from the pneumatic cylinder if by accident the
pedal is pressed.
With your finger, lift gently the safety ring to have
better access to the setting dies.
With an allen wrench loosen the set screw of the top
die and take it out.
1.
2.
3.
4.
Open the air inlet valve.
Axle of the pneumatic cylinder will go up.
Close the air inlet valve to have secure
access to the setting area.
In case top die is not free as in the picture,
remove it with your hand or a set of pliers.
With an allen wrench loosen the set screw of the
bottom die and take it out.
With your fingers, lift the setting dies and take them
out of the machine.
1.
2.
Take out the set screws (2) of the new dies.
Assemble the dies together. In order to cut
properly, the puncher of the top die enters
tight on the bottom die.
1.
2.
3.
Introduce the die on the setting area.
Placing bottom die on its original position.
Check that both holes for the set screws are
on the same side of the machine (in this
case right hand side).
1.
2.
Open the air inlet valve.
Press the safety pedal. Axle of the cylinder
will come down entering top die.
Close the air inlet valve so axle remains on
its lower position.
3.
1.
2.
3.
4.
Lift the safety ring to have better access to
this area.
Tighten firmly set screw from top die.
Tighten firmly set screw from bottom die.
Open air inlet valve and press the pedal
once to check that dies are working
properly.
6 MAINTENANCE.
There is no need to lubricate any mechanical parts of the machine.
For an optimum operation of the EP-200 it is important to have some parts clean, and this operation should
always be done with a) the main air inlet valve on position “OFF” and b) the main switch on “OFF” position (no
light on).
The raceways where eyelets and washers come down should be always kept clean; we recommended doing it at
the end of the day with compressed air. Any threads or small parts on the raceways may stop the eyelets and
washers from coming down.
It is important to clean setting area, especially the top die where threads will remain on the puncher as marked
on Fig. 9.
Fig. 9
We recommend doing it with an air gun through the open space on the safety cover in the front of the machine.
This operation should be done at least once per day, but depending upon the type of materials used might be
necessary to increase the timing between cleaning.
The push button should always be clean and clear of any parts that could interfere on its normal operation.
The outer parts of the machine should be cleaned with a cloth that will leave no threads.
If the machine is going to be a long period with no use please follow these recommendations:
1.
2.
3.
Disconnect it from the compressor
Clean it.
Cover it to avoid humidity and dust.
It is important that the machine is connected to a compressor or local air installation with an air filter.
7 FAILURES.
7.1 TROUBLESHOOTING.
PROBLEM
CAUSE
SOLUTION
8 SAFETY.
8.1 SAFETY DEVICES.
9 ANNEX.
9.1 SPARE PART LISTING.
REFERENCE
DESCRIPTION
9.2 SUPPLIED TOOLING.
REFERENCE
ALLEN # 3
9.3 PNEUMATIC DRAWING.
DESCRIPTION
QUANTITY
1
9.4 GUARANTIES.
Model EP-200 has a guarantee period of 12 months since purchasing.
Within this period, Spandex will replace free of charge all spare parts that under Spandex
knowledge have manufacture defects
The guarantee will not cover assemble / disassemble of the unit but will cover their freight cost.
The guarantee will not cover those parts with normal wear for the machine use as the setting dies.
www.spandex.com